Apparatus for heat and vacuum-pressure machine molding

ABSTRACT

Apparatus and methods for heat and vacuum-pressure machine molding of hollow articles from thermoplastic sheet material, involving a mold (normally with alternate vacuum and air pressure sources) having one or more relatively movable complementary molding members for forming undercut, reverse band, flanged or reentrant portions of said articles, with said member or members being mounted for relative movement, with respect to the molding surface of the mold, into molding position, and thereafter out of such molding position so that a molded article may be freely removed from said mold, said complementary molding member or members being preferably actuated by or through contact with and relative movement of the plastic sheet material by vacuum, with or without the aid of a plug-assist, e.g. where a female external mold is employed.

United States Patent [72] Inventor James W. Jackson Est WMM [211 App1.No. 771,576 [22] Filed Oct. 29, 1968 {45] Patented May 4, 1971 (73] Assignee Bird I: Son, Inc.

Fast Walpole,

[54] APPARATUSFOR HEAT ANDVACUUM- PRESUREMACHINE MOLDING 7 Claim, 16 Drawing! [52} US. 18/ 19, 18/35 {511 1nt.Cl. ..B29c17/04, 829:: 23/ [50] l leldotseareh 18/19 (A), 19 (P), 19 (B), 19 (E), 19 (F), 19 (H), 19 (M), 35, (undercut); 264/90, 91 92 {56] ltelereaeesChed UNITED STATES PATENTS 3,437,025 4/1969 Rice 95/39 2,688,156 9/1954 264/92 2,744,850 5/1956 18I19(BE)X 2,784,455 3/1957 18/35 2,830,322 4/ 1958 18/190314) 3,000,428 9/1961 Hansen et a]. 18/ 19(BM)X 3,018,518 1/1962 Jeffery: 18/190313) 3,126,582 3/1964 Scott 18/19(F) 3,205,535 9/1965 Niessner et a1, 18/19(TE)X FOREIGN PATENTS 1,237,243 6/1960 France ...18/.Undercut Digest 1,406,950 6/1965 France ...18/!Jndercut Digest 1,249,505 9/1967 Germany ..18/.Undercut Digest Primary Examiner-J. Spencer Overholser Assistant Exmniner-R. L. Spicer, Jr. Attorney-H. L. Kirkpatrick ABSTRACT: A mid methods for heat and vacuumure machine melding of hollow articles from thermoplastic sheet material, involving a mold (normally with alternatevaetmmandairpresureaornoes) havingoneormore relatively movable complementary molding members for forming undercut, reverse band, flanged or reentrant portions of said articles, with said member or members being mounted for relative movement, with respect to the molding surface of themold,intoposition,andthereafteroutofsuch misting nothatamoldedarticlenmybefreely removed from said mold, said oomplementary molding member or members being preferably actuated by or through oontact with and relative movement of the plastic sheet rmten'al by vacuum, with or without the aid of a plug-assist, e.g. where a female external mold is employed.

PATENTEUHAY 4|97l 3 577 593 sum 2 or 4 1 APPARATUS FOR HEAT AND VACUUM-E 7 MAIII-IINEMOIDING This invention relates to the fieldof heat and vacuumpressure molding of articles, principally hollow open-backed articles, from preheated thermoplastic sheet material and wherein said articles have undercut, flanged or reentrant portions, or the like, which necemitate the use of one or more cornplemen tary molding members relatively movable with respect to the molding surface of a main mold member first into molding position, and then, out of molding position,-thus to accomplish the removal of the molded articles. Various prior patents have been directed to the general end of the molding, from preheated flat thermoplastic sheet materials, of articles with various inwardly recessed or reentrant portions, for example, as in US. Pat. Nos. 2,784,455; 3,058,153; 3,l26,582; 3,172,927; and 3,302,245. None of these patents, however, discloses the apparatus or methods of this invention or having the simplicity, advantages, and capability of the novel apparatus and methods of this invention as hereinafter described.

The invention relates to an improved apparatus and methods for heat and vacuum-pressure forming of articles having inwardly undercut, reverse bend, flanged or reentrant portions, etc. from preheated thermoplastic sheet material, and is here shown and described, for example, in connection with the manufacture of hollow open-backed articles having reverse-bend flanges, specifically ornamental shutters for houses. The preferred novel apparatus and methods for making such products, as hereinafter described, involve a vacuumpressure female mold equipped with complementary heatconducting bodily movable metal molding means and the use thereof, the latter preferably being actuated, at least in part, by and through their contact with and relative movement of the preheated thermoplastic sheet. The invention is also applicable to male molds. The preferred combination also commonly includes though not ly, in addition, a plugassist, for forming from a preheated thermoplastic sheet material, of various unitary articles such, for example, as hol' low open-backed architectural shutters with reverse-bend inwardly facing flanges as here shown, for exterior use in houses, and similar building construction. Some similar shutters currently are partly handmade and include such zones and a principal object of the invention is to provide for simple, rapid, efficient, accurate and complete machine molding of various such or similar articles in regular economical commer- The features, objects, and advantages of the invention will adequately appear in considerable detail from the following description and drawing illustrating and describing preferred aspects of the invention, in which drawings:

FIG. 1 is an isometric view illustrating one type of article (here the external side of an architectural shutter, with one corner broken away, before edge trimming) which can be formed by the method and apparatusof the invention;

FIG. In is an isometric vi of a broken-away inverted cornerportionol'thearticleshownin FIG. 1;

FIG. lbisanisometricviewoftheoppositesideofthearticle shown in FIG. 1 but in trimmed condition, ready for sale and use;

FIG. 1c is an isometric view of a broken-away corner portionofthetrimmedmticlesown in FIG. lb;

FIG. 2 is an isometric view ol'the molding side of a female mold for vacuum forming of the article of FIGS. 1 through 10, here showing the complementary movable mold members in closed molding position;

FIG. 2a is an isometric view of a corner portion of the moldin; apparatus as shown in FIG. 1:

FIG. 3 la a similar view ol the apparatus of FIG. 2 but diffeo lag in that the complementary mold members are shown in open position alter removal of the molded article. thus permitted, and in position for starting the next molding cycle;

FIG. 3a is an isometric view of a corner portion of the apparatus as shown in FIG. 3; and

FlGS. 4-H show a series of d'mgrammatic vertical crosssectional views illustrating successive positions of the apparatus and molding steps of the method of the invention in the forming of the molded article of FIGS. 1 through lc.

Referring again to the drawings in which like numerals represent like parts,the molded untrimmed ornamental architectural shutter, simulating a wooden shutter, generally designated 10, includes a main portion 12, edges 14, and integral inwardly flanged portions I6, extending continuously (or not) around the inner open-backed perimeter of the shutter proper. As molded, before trimming (FIGS. 1 and la), each said flange 16 constitutes a portion of the recntrant recess, the lower half of which is subsequently cut away, as will appear by a comparison of the untrimmed shutter of FIGS. 1 and to with the trimmed article of F168. 1!: and lc.

FIGS. 2 and 3 are isometric views of the active molding side of a female mold, generally designated 18, suitable for forming the shutter of ROS. l and la. Each such FlG. shows the interior of the vacuum mold and four movable complementary metal mold members 20, hinged to l8, as appears in FIGS 2a and 34, for forming the intumed flanges l6, each of said mem here 20 having its ends mitered so as to provide four integral molded flanges 16 by reason of the end-mitered members 20 when closed and in molding position, as shown in FIG. 2, as compared with their open position as in FIGS. 3 and 3a, permitting the removal of the molded article of HO. 1, and ready to receive another plastic sheet to be molded.

The preferred apparatus and successive steps of the method will be evident from the drawings of FlGS. 411 comprising a series of diagrammatic vertical cross-sectional views, of a portion of the apparatus, illustrating the successive positions of the apparatus in molding and successive steps in forming the article of FIGS. 1 and In, for example.

FIG. 4 illustrates the conventiontd holding of a preheated plastic sheet 24 by means of paired sets of sheet clamps 26, four sets of which are normally employed around the perimeter of rectangular sheet as here; H6. 5 shows the clamped horizontal heated sheet held in position underneath the vacuum mold by means, not shown, about to be vertically moved (by conventional means not shown) relatively to the mold in a direction transverse to the sheet material. Such movement causes the sheet initially to contact the bottom edges of the complementary mold members 20, hinged at 22, which members 20 depend downwardly from adjacent the bottom margin of mold 18. As also shown in FIGS. 4 and 5, the hinge members so pivoted are shown as limited to about a 60 depending position with respect to the horizontal, and thus are readily liltable about their pivots by their contact with and relative movement of the sheet to the successive positions shown in FIGSv 6, '1 and 8, as the sheet 24 is lifted by the relative vertical movement of the clamps 26 and sheet with respect to the cavity of female mold 18.

Though this result can be accomplished in the absence of a plug-assist, it is preferred to employ a common vertically movable plug-assist 32, shown contacting the sheet in H68. 6- Il3, as an aid to moving the sheet, but primarily to aid in maintaining a more uniform thickness of the molded sheet prior to the first application of the vacuum (between the mold and the sheet, sealed at 30) which allows vacuum and atmcspheric pressure (indicated by arrows in FIG. 9) to force the sheet from the position shown in FIG. 8 to that shown in FIG. 9, so that the sheet fully contacts the horizontal and vertical surfaces of the vacuum mold and, at the same time, causes it to conform and to be shaped by the shape of the complementary mold members (see FIG. 9) to provide the intumod flanges Id at the upper side of the reentrant angle portions of the untrlmmed article of FIGS. 1 and la. Thus, atmospheric pressure may be supplemented by mechanical (e.g. plug-assist or other) forming means or not, depending somewhat on the size of the article. It will be appreciated that, strictly speaking, the vacuum does not form the sheet but, instead, makes available a pressure differential that enables atmospheric pressure (normally 14.7 psi.) to form the hot plastic sheet. Also,

3 if necessary, in some applications atmospheric pressure may be supplemented by an air pressure box mounted outside of the plug-assist that permits air pressures up to two or three times that of the atmosphere to be used for forming the hot plastic sheet, as provided by currently used apparatus and techniques in the art.

In the absence of a plug-assist, it will be appreciated that the full combination shown in FIG. 8 is not employed, in that the sheet moves directly from the position shown in FIG. 6 to that of FIG. 9 due solely to the influence of atmospheric air pressure and the hijr vacuum employed (e.g. of the order of 27.1 -28" mercury).

From FIGS. 10 and 11 it will be appreciated that air pressure applied from within the molds (indicated by arrows) aids gravity in the ejection of the molded article, as is preferred, though such is not always necessary. It will also be seen from these FIGS. that the complementary mold members, as is preferred, swing down by gravity, first, to partially clear the molded article, as in FIG. 10, and then, to the depending position of FIG. ll, again asuming the depending 60 angle as shown and described in connection with FIGS. 4, 5 and 6,

- ready for the next molding cycle.

Though the heated and presoftened sheet is described herein as thermoplssticf' as is physically in fact the case during formation of the molded article, it may be constituted of material chemically thermosetting at some late stage of or after molding.

The description herein, as previously mentioned, largely directed to the use of a female mold by way of example, includes various aspects and features also applicable to male molds having one or more complementary movable mold members and the use thereof, and hence various claims hereof are intended to cover both types and other clairm each type.

For the purposes of the appended claims, the word reentrant" is intended to include various articles having undercut, reverse-bend, and internally flanged portions, as well as articles having strictly reentrant portions.

I claim:

1. In an apparatus having a vacuum mold with a vacuum molding surface for vacuum molding articles from hot ther moplastic sheet material by direct contact with said molding surface and with mechanical means for effecting relative movement of the mold and sheet in a direction transverse to said sheet material into contact with said molding surface, wherein the improvement comprises:

at least one movable complementary mold member hingedly mounted on said mold for separate relative movement, solely through sheet contact therewith and sheet movement prior to contact of said sheet with said molding surface, into and out of sheet molding position with respect to the said molding surface of said mold, thereby to provide localized sheet formation corresponding to the complementary mold member due to the sheet contacting the member surface and the relative movement thereof between said member and said sheet, and said member permitting withdrawal from the mold of the final molded article.

2. The of claim 1 wherein the complementary mold member is hingedly mounted at right angles adjacent the margin of said molding surface.

3. The apparatus of claim 2 wherein the complementary mold member is hingedly mounted and depends downwardly by gravity at an oblique angle at initial sheet contact and swings during sheet movement to final molding position.

4. In an apparatus for vacuum molding articles from hot thermoplastic sheet material by direct contact with a molding surface,

a vacuum mold having a molding surface,

at least one complementary movable mold member hingedly mounted adjacent the margin of said molding surface for movement into and out of inwardly extending molding position with respect to said molding surface, a plug-assist mounted an adapted for relative vertical movement into and out of molding relation with such movement correlated with said complementary mold member movement into and out of molding position to provide reentrant molding of a marginal portion of said sheet material and to permit removal of the molded product,

said mold member being moved solely by contact with said sheet prior to contact of said sheet with said molding surface.

5. In apparatus for vacuum molding articles from hot ther moplastic sheet material,

a vacuum mold having a rectangular molding surface,

four complementary movable mold members hingedly mounted at right angles adjacent the margin of said molding surface for swinging movement into and out of inwardly overlapping molding position with respect to said molding surface,

a plug-assist mounted and adapted for relative movement into and out of molding relation whereby it relative movement correlated with said complementary mold member movement into and out of molding position to provide reentrant molding of said sheet material near the margin of said molding surface and to permit removal of the molded product.

6. In an apparatus for vacuum molding articles from hot thermoplastic sheet material clamped and held by its edges in said apparatus for direct contact with a molding surface,

a female vacuum mold on one side of the sheet having a mold cavity with a molding surface facing the sheet,

at least one complementary movable mold member hingedly mounted adjacent the margin of said cavity and on one side of said sheet, said sheet mounted for movement into and out of inwardly overlapping molding position with respect to said mold surface,

a male plug-assist on the opposite side of said sheet mounted and adapted for relative movement into and out of said mold cavity whereby its relative movement and that of the intervening sheet material control complementary mold member movement into and out of molding position to provide reentrant molding of a portion of said sheet material and to permit removal of the molded product,

said mold member being moved solely by contact with said sheet prior to contact of said sheet with said molding surface.

7. In an apparatus for vacuum molding articles from hot thermoplastic sheet material clamped and horizontally held by its edges in said apparatus for direct contact with a molding surface,

a female vacuum mold on the upper side of the sheet having a mold cavity with a molding surface facing the sheet,

at least one movable complementary mold member hin gedly mounted at right angles adjacent the margin of said cavity and on the suction side of said sheet for swinging movement from a downwardly depending position into and out of inwardly overlapping molding position with respect to said mold surface,

a male plug-assist on the bottom side of said sheet mounted and adapted for relative movement into and out of said mold cavity whereby its relative movement and that of the sheet material control complementary mold member movement into and out of molding position to provide reentrant molding of a portion of said sheet material and to permit removal of the molded product,

said mold member being moved solely by contact with said sheet prior to contact of said sheet with said molding surface. 

1. In an apparatus having a vacuum mold with a vacuum molding surface for vacuum molding articles from hot thermoplastic sheet material by direct contact with said molding surface and with mechanical means for effecting relative movement of the mold and sheet in a direction transverse to said sheet material into contact with said molding surface, wherein the improvement comprises: at least one movable complementary mold member hingedly mounted on said mold for separate relative movement, solely through sheet contact therewith and sheet movement prior to contact of said sheet with said molding surface, into and out of sheet molding position with respect to the said molding surface of said mold, thereby to provide localized sheet formation corresponding to the complementary mold member due to the sheet contacting the member surface and the relative movement thereof between said member and said sheet, and said member permitting withdrawal from the mold of the final molded article.
 2. The apparatus of claim 1 wherein the complementary mold member is hingedly mounted at right angles adjacent the margin of said molding surface.
 3. The apparatus of claim 2 wherein the complementary mold member is hingedly mounted and depends downwardly by gravity at an oblique angle at initial sheet contact and swings during sheet movement to final molding position.
 4. In an apparatus for vacuum molding articles from hot thermoplastic sheet material by direct contact with a molding surface, a vacuum mold having a molding surface, at least one complementary movable mold member hingedly mounted adjacent the margin of said molding surface for movement into and out of inwardly extending molding position with respect to said molding surface, a plug-assist mounted and adapted for relative vertical movement into and out of molding relation with such movement correlated with said complementary mold member movement into and out of molding position to provide reentrant molding of a marginal portion of said sheet material and to permit removal of the molded product, said mold member being moved solely by contact with said sheet prior to contact of said sheet with said molding surface.
 5. In apparatus for vacuum molding articles from hot thermoplastic sheet material, a vacuum mold having a rectangular molding surface, four complementary movable mold members hingedly mounted at right angles adjacent the margin of said molding surface for swinging movement into and out of inwardly overlapping molding position with respect to said molding surface, a plug-assist mounted and adapted for relative movement into and out of molding relation whereby it relative movement correlated with said complementary mold member movement into and out of molding position to provide reentrant molding of said sheet material near the margin of said molding surface and to permit removal of the molded product.
 6. In an apparatus for vacuum molding articles from hot thermoplastic sheet material clamped and held by its edges in said apparatus for direct contact with a molding surface, a female vacuum mold on one side of the sheet having a mold cavity with a molding surface facing the sheet, at least one complementary movable mold member hingedly mounted adjacent the margin of said cavity and on one side of said sheet, said sheet mounted for movement into and out of inwardly overlapping molding position with respect to said mold surface, a male plug-assist on the opposite side of said sheet mounted and adapted for relative movement into and out of sAid mold cavity whereby its relative movement and that of the intervening sheet material control complementary mold member movement into and out of molding position to provide reentrant molding of a portion of said sheet material and to permit removal of the molded product, said mold member being moved solely by contact with said sheet prior to contact of said sheet with said molding surface.
 7. In an apparatus for vacuum molding articles from hot thermoplastic sheet material clamped and horizontally held by its edges in said apparatus for direct contact with a molding surface, a female vacuum mold on the upper side of the sheet having a mold cavity with a molding surface facing the sheet, at least one movable complementary mold member hingedly mounted at right angles adjacent the margin of said cavity and on the suction side of said sheet for swinging movement from a downwardly depending position into and out of inwardly overlapping molding position with respect to said mold surface, a male plug-assist on the bottom side of said sheet mounted and adapted for relative movement into and out of said mold cavity whereby its relative movement and that of the sheet material control complementary mold member movement into and out of molding position to provide reentrant molding of a portion of said sheet material and to permit removal of the molded product, said mold member being moved solely by contact with said sheet prior to contact of said sheet with said molding surface. 